RCM Release 3.13B

December 2020

IMS RCM is used to develop a Maintenance strategy for Equipment based on a Reliability Centred Maintenance assessment. The following release notes describe the new functionality and improvements in version 3.13B.

In addition to the stabilizations, version 3.13B contains added levels of optimisation to MEC Optimisation board, improved Pump Cards, MEC Costs, Shared Maintenance Libraries functionality, etc.

Improved checklists and condition history

1. New checklist for motors

IMSFB-17051

Based on years of experience in the industry, RCM now brings new checklist to the RCM Condition history for the motors! When performing an inspection on a motor, you can now use the checklist to capture all relevant findings. The checklist has four stages:

1. General information about the motor,
2. Visual inspection of motor,
3. Inspection of starter / contactor, and
4. Measurements of the resistance, absorption, and injection test.

Figure 1: Checklist for LV Motors.

 

2. RCM now selects default checklists

IMSFB-16753

RCM now auto-selects the checklist for the condition history, when creating a new condition history. If there is only one checklist, RCM auto-selects that checklist. In case where there are more than one, a preferred checklist can be configured to be auto-selected. Users can always change the selected checklist to a more appropriate one, if needed.

Figure 2: Auto-selected checklist for a MOTOR Equipment ECH.

 

3. Set stage to “not applicable”

IMSFB-16748

If you are completing a checklist, and some parts are not applicable, you can just click on “Done?” and confirm your choice. RCM then disables all the fields: captured values become unchangeable and the empty fields are greyed-out.

If none of the fields in the stage are filled in, RCM will classify that stage as “Not applicable” and colour it grey. If there is at least one filled-in field, the stage is set to: “User set as completed”, and the colour goes to green, even though only some fields are filled in.

Figure 3: Stage set to Not applicable.

 

4. Dashboard for pumps

IMSFB-16751

For a better pump overview, RCM now provides a dashboard which provides an overview of pumps per stage, as defined in the condition history checklist.

If pumps have open condition histories, you can track the progress of every stage for those pumps. The dashboard can answer question such as: How many stages can be approved?; How many pumps have bearing checks in progress?; What stages need to be completed for selected pump?; etc.

Figure 4: Pump overview dashboard.

 

5. Improved look and feel of a condition history

To standardize the look and feel of condition histories in IMS, condition histories now shows schedules, which can be credited, as cards. These schedules can now also be credited with just one click on the card, instead of the previous three clicks!

Figure 5: Crediting a schedule with just a click.

 

Also, the created schedules are shown as cards. This way you have a better overview to see which schedules were credited, and which schedules were created as a result of the condition history. Buttons have also been added, to quickly create desired schedule types.

Figure 6: Quick buttons for creating the schedule of a specific type.

 

6. Add drawings to the condition history

You can now use IMS functionality to attach drawings to your condition history! Search your drawing database and import them to IMS. This will make your inspection easier and more detailed.

After importing the drawing, you can use the annotation tools to make notes and save them to your attachments.

Figure 7: Drawings on condition history.

 

Cost KPI for MEC

IMSFB-15962

1. Configuring MEC Costs per module

The MEC costs on schedules can be mandatory or optional, depending on the site’s configuration. By default, the IMS modules are configured as follows:

• MEC Costs mandatory: RCM
• MEC Costs optional: PEI, PLSS, TAT

This can be configured by defining optional modules in the application settings.

In addition, specific schedule types, on which MEC Costs are used, can also be listed. By default, IMS is configured to show MEC costs on inspection, corrosion, CAIR and preventive schedules.

Figure 9: Application setting for configuring MEC costs.

 

2. Visibility of MEC Costs for every user

If the MEC costs are set as mandatory, the schedules in that module will show the costs. However, if the MEC costs are set as optional for the module, by default the costs will not be shown on the schedules.

Nevertheless, in a module for which MEC Costs are optional, a user can still turn on the visibility of MEC Costs for himself. This can be done in the user settings (see Figure 10). This setting will not be available in modules for which the MEC Costs are set to be mandatory.

Figure 10: User settings for turning on MEC Costs in optional modules.

 

The visibility of MEC Costs is summarized in Table 1. The visibility depends on the application setting (Mandatory vs Optional) and, in the Optional case, it also depends on the user setting (Turned on vs Turned off).

Table 1: Visibility of the MEC Costs.

3. MEC Costs features

When the MEC Costs are visible, the following features are available:

3.1 Defining cost of a schedule

In modules, with the MEC Cost set as optional, the costs are shown with a subtle button.

Figure 11: Showing MEC Costs in optional modules.

 

When you click the cost button, a cost breakdown will be shown in an expanded view (see Figure 12). This view is the default view for modules with the MEC Cost set to mandatory.

For a schedule, the costs can be defined as a complex cost, consisting out of labour costs, material costs and misc. costs. However, the cost can also be defined as a simple total cost. In this case the other cost categories will not be editable.

Figure 12: Costs breakdown and defining cost on a schedule.

 

Note: The approval status of a schedule will not be impacted when the costs are being defined, i.e. a schedule that is in final approval state will not go back to draft when the costs are entered.

3.2 Defining default schedule costs

To make it easier to define the costs, default costs can be defined for schedules, depending on their properties. Default costs can be defined with following properties:

• Location default
• Equipment group
• Equipment/SAP type
• Schedule type
• Schedule driver
• TA candidate status
• Plan codes

This default cost configuration can be configured in:

Settings à Top level à Select location à MEC Cost

Figure 13: Example of default cost rules.

 

The following logic is used to determine the default costs for a specific schedule:

• Use the location default checkbox to define a cost specific only for this part of the hierarchy. This is a “safety net” for when no other criteria is met.
• Define default cost by using Equipment group, SAP type, schedule type, schedule driver, TA Candidate status and plan codes.
• In cases where a schedule meets multiple criteria, IMS will suggest the higher cost as a default cost.
• In cases where a schedule meets multiple criteria that differs only in terms of plan codes, IMS will sum the values and suggest their sum as a cost.

To help make this process easier, there is now also an import for the default cost configuration, and an export button is visible on the MEC Cost grid.

3.3 Using default cost on a schedule

When a schedule is being created, IMS will look up the default cost for this schedule. This cost will be captured and saved by default. The user can remove the default cost and enter a more accurate cost.

When plan codes are used, the scope needs to be final approved before IMS captures the SUM of the costs, which is defined for each plan code.

To remove the default cost, click on a checkbox. This will enable the fields so that different costs can be entered.

Figure 14: Example of a schedule with the default cost.

 

3.4 Defining Schedule costs via the import

To define the costs faster, a dedicated export for import was made: Check the desired schedules in the grid and click the export button. Two new options for exporting costs will then be shown. By selecting one of these the schedule id and relevant information, with regards to determining the costs, will be exported. The exported template can then be filled in and imported back into the IMS.

Figure 15: Export for import and import template for schedule costs.

 

3.5 Determining annual cost

A schedule’s total cost is annualized if the schedule is recurring. If a schedule is not recurring, IMS will assume that the schedule represents a one-time job, and the annual cost will be the same as the total cost.

The annual cost is defined by the following formula:

The annual cost is only for a schedule when there is a defined interval. A schedule also needs to be approved before the annual cost is calculated (if the interval is added afterwards).

Figure 16: Example of a schedule with an annual cost.

 

3.6 Determining if a cost is TA or Non-TA

Depending on the schedule characteristics, a cost can also be classified as a turnaround or non-turnaround cost.

This is decided based on two schedule properties:

• TA candidate flag
• Connection to a planned event

If one of those conditions are met, the schedule cost will be considered as a TA cost. Otherwise, cost will be considered as non-TA cost. This is also indicated by the heading of the schedule cost.

Figure 17: Example of a schedule with TA cost.

 

3.7 Showing costs in schedule grid

Total costs and annual costs can be shown in the Schedule main grid. Those options are by default not visible, but a user can turn them on in the grid.

Figure 18: Showing total and annual cost in schedule grid.

 

3.8 Filtering on schedule cost

On the Schedule main grid, two additional filters are also available.

The first filter is a range filter for the total schedule cost.

The second filter can be used to find schedules with no cost defined, schedules with default cost, and schedules with defined cost.

Figure 19: Schedule cost filters.

 

4. MEC Cost index

Once schedule costs are defined, it is time to calculate the MEC cost index. The MEC Cost index is calculated based on the following formula:

The MEC Cost index is calculated for a specific year and for a specific location (site, plant or unit).

The annual costs are based on:

• Annualized costs for the schedules
• Annual POC on the tasks (RCM)

The benchmark factor is determined by the user, for a specific year.

The cost for a specific year is determined based on the schedule’s next inspection date (due date). If a schedule is overdue, the year is assumed to be the current year.

4.1 Annual POC on tasks

Annual costs of schedules are determined as explained previously (see 2.3.5). To these costs, IMS then adds an annual Price of Conformance (POC), which can be found on tasks in RCM.

The cost is classified as a TA cost if the task has a “TA Candidate” flag. The task cost is also ignored if a task has a “Merged to Task” flag.

Figure 20: Annual POC on tasks.

 

4.2 Calculating MEC Cost index per specific year

To calculate the MEC cost index, got to:

Settings à Top level à Select location à MEC Cost

The MEC Cost tab is used to define a group, year and a benchmark index for that year. For example, multiple locations can be reported as one – select in “Cost Configuration” group under which current location should be reporting as.

Figure 21: MEC Group definition.

 

When ready, click the calculate button in the upper right corner. IMS will then summarise the costs (from schedules and tasks), apply the default costs (if the rules changed), and calculate the MEC Cost index based on the summarised costs.

The calculation takes in consideration all active Equipment, except the ones in status “IN CONSTRUCTION”, and active and approved schedules (schedules in final approval state).

Figure 22: Example of MEC Cost index calculation.

 

Click on the + button in the grid, to add a “Year” and a “Benchmark Factor”. The “Index Type” indicates the nature of the benchmark factor but does not play a role in the MEC Cost index calculation.

Figure 23: Creating new yearly record.

 

Table 2: Cost Configuration example.

4.3 Overview of Benchmarks

To see all reporting groups and available years, click on “OPCO” in the settings. Settings à Toplevel à OPCO

There you can see the reporting “MEC Groups” and all Cost configurations.

Figure 24: Overview in OPCO.

 

5. MEC Cost dashboard

A MEC Cost dashboard is available to help track your costs. The dashboard shows: Schedules with costs; Number of Equipment which have at least one schedule with a cost; and Number of schedules without defined costs. To get a deeper insight in the costs, you can also drill down to see the costs per site, Equipment group and year.

The dashboard also shows an overview of all MEC Cost indexes, on all locations for which a year and a benchmark is defined.

Figure 25: MEC Cost dashboard.

 

MEC Optimization Board

1. MEC Optimization Board Slide panel

IMSFB-17113

A slide panel, containing buttons for various MEC functionalities, was added. In this way, the cards themselves were made more compact and user-friendly.

The Slide Panel opens with a “Sandwich” button:

Figure 26: Slide Panel button.

 

The Slide bar is then opened, containing various functionalities, now appliable to multiple selected tasks at the same time. Those are:

• Merge Tasks
• Mandatory Task
• TA Candidate
• Task Requirements
• Add Labels
• Delete

When working with RSL, the following additional functionalities are also available:

• Mark RSL missing tasks
• Mark RSL matching task
• Align to RSL task

Figure 27: The Slide Panel.

 

1.1 Merge tasks to max / min frequencies

For merging of the duplicate tasks, an option to choose the frequency to which the tasks should be merged, was added. Now tasks can be merged to:

• The lowest frequency of the duplicate tasks; or
• The highest frequency of the duplicate tasks (default).

Figure 28: Merge tasks to lowest / highest frequency.

 

1.2 Mandatory / TA Candidate

The “Mandatory and TA Candidate” panel can be used to mark all selected tasks as Mandatory or NOT Mandatory, and as TA Candidate / NOT TA Candidate.

Figure 29: Mandatory and TA Candidate panels.

 

1.3 Task Requirements

The Task Requirements panel can be used to add tasks requirements, as explained in chapter 6.1.

Figure 30: Task Requirement Panel.

 

1.4 Add Labels

The “Add Label” panel can be used to add labels directly from the MEC Optimization Board.

Figure 31: Add Labels panel.

 

1.5 Mark RSL missing tasks

An option was added to mark all the tasks, which are contained in the currently selected RSL (for an Equipment Group) and are not assigned to FLOC / Equipment on the MEC optimization board. This option becomes visible when the RSL swimlane is opened. It compares the tasks in both swimlanes and marks, with a red-dotted line, the missing tasks in the RSL swimlane.

Figure 32: Mark RSL missing tasks.

 

1.6 Mark RSL matching task

An option was added to mark all the tasks, which are both present on the Tasks swimlane and in the currently selected RSL. This option becomes visible when the RSL swimlane is opened. It compares the tasks in both swimlanes and marks, with coloured dotted lines, the groups of tasks that are in both swimlanes.

Figure 33: Mark RSL matching tasks.

 

This functionality is useful with regards to aligning task frequencies to RSL tasks, since it provides clear information about the tasks that can be aligned and to which frequencies.

Figure 34: Marked RSL matching tasks.

 

1.7 Align tasks to max / min frequencies of the RSL tasks

For aligning of the tasks to the RSL tasks, an option was added to choose the frequency to which the tasks should be aligned to. Now tasks can be aligned to:

• The RSL task with lowest frequency; or
• The RSL task with highest frequency.

Figure 35: Align tasks to lowest / highest frequency.

 

2. Main Timeline

2.1 Added counts and checkmarks to main timeline

IMSFB-17108

Counts and checkmarks for all Optimisation Levels were added to the Main Timeline.

Figure 36: MEC Optimisation board Main timeline counts and checkmarks.

 

The counts show the following information:

• First number: The number of FLOCs/Equipment with the level marked as “Completed”.
• Second number: The total number of FLOCs/Equipment loaded.

The checkmarks show the following info:

• No checkmark (empty circle): None Completed.
• Yellow checkmark: Some of the loaded FLOCs/Equipment are marked as Completed.
• Green checkmark: All the loaded FLOCs/Equipment are marked as Completed.

The checkmark colouring logic is applied to the main stages (Equipment, System), as well.

3. Main optimization levels

System and Unit optimization levels were added, to guide the user through the steps of MEC optimization on functional systems and assets. These are:

• Optimize run Limiters,
• Align Timing,
• Optimize High-Cost Equipment (types),
• Optimize complex and expensive tasks, and
• Optimize Risk profile.

3.1 Optimize Run Limiters

The intent of the “Optimize Run Limiters” level is to show the tasks that determine the minimum time that an Equipment or a system can run uninterrupted.

The default filters values are:

• The first system;
• Task is approved i.e. MEI > [setting] and/ or Mandatory =true; and
• Run limiter system = true.

3.2 Align Timing

The intent of the “Align Timing” level is to show and optimize tasks that are on-the-run, i.e. that do not require Turnarounds, on Functional System level.

The default filters values are:

• The first system;
• Task is approved i.e. MEI > [setting] and/ or Mandatory =true; and
• TA task = NO.

3.3 Optimize High-Cost Equipment (types)

The intent of the “Optimize High-Cost Equipment and Types” level is to show and optimize the Equipment and Equipment Types, loaded on the MEC Optimization board, that are the most expensive.

The default filters values are:

• The first system;
• Task is approved i.e. MEI > [setting] and/ or Mandatory =true; and
• Cost Stats – High-Cost Equipment OR High-Cost Equipment Types.

3.4 Optimize complex and expensive tasks

The intent of the “Optimize complex and expensive tasks” level is to show and optimize Equipment that require complex conditions and requirements to be fulfilled.

The default filters values are:

• The first system;
• Task is approved i.e. MEI > [setting] and/ or Mandatory =true; and
• Task Requirement -> All tasks with requirements turned on.

3.5 Optimize Risk profile

The intent of the “Optimize Risk profile” level is to show and optimize Equipment that have a high Residual Risk value.

The default filters values are:

• The first system;
• Task is approved i.e. MEI > [setting] and/ or Mandatory =true; and
• Residual risk: >M.

3.5.1 Benchmark

The “Benchmark” level for System and Unit Optimisation will be included in one of the future releases.

4. Levels filters

4.1 Added Task Annual POC / Schedule MEC Costs filter

IMSFB-17117

The “Task Annual POC / Schedule MEC Costs” filter was added to the level filters bar, as a range filter. This enables the user to focus on tasks / schedules of a certain cost range.

This filter considers the information merged from two sources:

• The task Annual POC for RCM tasks; and
• The schedule MEC Costs for PEI schedules.

Figure 37: Task Annual POC / Schedule MEC Costs filter.

 

Task Annual POC / Schedule MEC Cost information was added to the cards, as well.

Figure 38: Task Annual POC / Schedule MEC Cost information on card.

 

4.2 Added Task Requirement filter

IMSFB-17299

A “Task Requirement” filter was added to the level filters bar, enabling the user to filter the task cards based on the Task Requirements (new feature described in chapter 6.1).

Figure 39: Task Requirement filter.

 

4.3 Added SCHEDULE next to Task in filter labels

IMSFB-17084

For all filters, relying on the RCM tasks OR PEI schedules, the labels were changed to “Task/Schedule”.

Figure 40: Tasks/Schedule labels.

 

5. Task Cards

5.1 Task Cards redesigned

Task cards were redesigned and made more compact and user-friendly.

5.2 MEC board: Show task Id in Task card

IMSFB-17057

The Unique Task Id Number was added to the Task Card.

Figure 41: Unique Task Id Number on card.

 

Sharing Maintenance Libraries

IMSFB-16621

A functionality to share a local Maintenance Library, as SHARED to the GLOBAL site, was added. Additionally, the functionality to create a local copy, based on the shared RSL, has also been developed.

The main difference between the GLOBAL and the SHARED RSLs is that the GLOBALs are maintained and appliable directly on/from the GLOBAL server by a GLOBAL RSL Custodian, while the SHARED are shared between the sites and must be localised and approved before they can be applied.

The buttons for this functionality were added to a new section on the toolbar.

Figure 42: Shared RSL buttons.

 

1. Sharing a local RSL to the GLOBAL site

A Local Maintenance Library can now be pushed to the Global Site. This makes it available, through the Shared RSL Library, to the whole RCM community. This can be performed with certain limitations:

• The Maintenance Library is in FINAL APPROVAL status;
• The Shared Maintenance Library, with the same name and revision, should not already be shared from the same site; and
• The Shared Maintenance Library will be created in DRAFT status.

Figure 43: Shared RSL library button.

 

Shared RSLs are marked with a “Shared” indicator in the Shared column, in the Maintenance Library main grid.

Figure 44: Shared indicator.

 

The same status can be shown / filtered out, through the Sharing filter.

Figure 45: Shared filter.

 

The user can stop (revoke) sharing once shared with RSL, by pressing the “Stop sharing RSL” button.

Figure 46: Stop sharing to Shared library button.

 

This will remove the RSL from the Shared library, and it will no longer be available to the community. If a site created a localised copy of a shared RSL, it would get a warning that the original RSL is not shared anymore.

Figure 47: Revoked Shared RSL indicator.

 

2. Shared RSL library / Getting a Shared RSL to the local site

A Shared Maintenance Library can be downloaded from the Shared Library. This makes it available locally for eventual customizations and approval. This can be performed with certain limitations:

• The user must have the RCM Admin role;
• The Local Maintenance Library with the same name should not already exist; and
• The Local Maintenance Library will be created in DRAFT status (even if it is already approved globally).

Figure 48: Open Shared library / Download Shared RSL button.

 

In the Shared RSL library window, all shared libraries are listed, and the creating users, sites and dates are shown. The list can be searched and filtered out on the Sharing site.

Figure 49: Shared RSL Library.

 

3. Allow renaming the RSL when getting it from the Global Site

IMSFB-17004

A functionality was added that enables the user to rename the Maintenance Library, when creating a localized version. This applies to GLOBAL RSLs, as well as to SHARED RSLs.

A pop-up is shown with the original name prefilled. If the user wants, he can then change the name.

Figure 50: Renaming the local RSL.

 

4. Open an RSL upon getting it from the Global Site

IMSFB-17006

When downloading a GLOBAL or SHARED RSL library, the user is automatically directed to its details screen, allowing him to edit or approve the localized version.

Figure 51: Downloaded RSL details section.

 

Dashboards

1. RCM dashboard changes

The RCM Dashboard has been re-created using the new dashboarding tools. Also, the Equipment Status filter has been added, to show the Equipment with “CONSTRUCTION” status.

The old RCM dashboard has been renamed to “RCM Dashboard (legacy)”.

Figure 52: RCM Dashboard.

 

2. Global dashboard changes

The Global dashboards have been updated to match the IMS-Portal’s visual style.

Figure 53: RCM Global Dashboard.

 

Various usability enhancements

1. Added Task Requirements functionality

IMSFB-17299

A functionality was created for adding specific task requirements and conditions, which must be fulfilled before the task can be carried out. Task Requirements are categorized into Requirement Types and the list can be configured locally, per site, using the Settings screen.

Figure 54: Settings - Task Requirements.

 

The “Task Requirement” functionality is available from two screens:

• The Tasks main grid; and
• The MEC Optimization Board.

Figure 55: Task Requirements button.

 

The functionality is available for bulk assignments. Thus, a user can select multiple tasks at the same time, and then click the “Task Requirement” button.

Figure 56: Task Requirements dialogue box.

 

In the pop-up, there are drop-downs for choosing Requirement Type and Name and a free text field for entering a Remark. Uniqueness is determined based on Type and Name.

The + and – buttons can be used to add multiple requirements to multiple tasks at the same time.

Task Requirements are shown on the Task details pop-up.

Figure 57: Task Requirements on Task details pop-up.

 

The Task grid can be filtered out using the “Task Requirements” filter.

Figure 58: Task Requirements filter.

 

2. RSL Reason for edit

When approving a new revision, the “Reason for Edit” is a mandatory field. Now this field is displayed on three screens, to make this information more prominent to the users:

• The “Reason for Edit” was added to the Maintenance Library main grid as a column;
• The “Reason for Edit” was added to the FLOC / Equipment grid as a tooltip, indicating that FLOC / Equipment is Out of sync; and
• The “Reason for Edit” was added to the RSL Dashboard in the Recent update section.

Figure 59: The “Reason for Edit” on the Maintenance Library.

 

Figure 60: The “Reason for Edit” as a tooltip on the FLOC/Eq grid.

 

Figure 61: The “Reason for Edit” on the RSL Dashboard.

 

3. Settings – RCM Specific Data folder reorganized

The settings screen was reorganized to group all Task related settings into one subsection.

Figure 62: Reorganized settings screen.

 

4. Analysis Completeness filter added to FLOC/Equipment main grid

IMSFB-17071

The RCM Analysis “Completeness” filter was added to the FLOC/Equipment main grid.

Figure 63: Completeness filter.

 

5. MEC Optimization Level filter added to FLOC/Equipment main grid

IMSFB-17118

The “MEC Optimization Level completed” filter was added to the FLOC/Equipment main grid.

Figure 64: MEC Optimization Level completed filter.

 

6. Analysis completeness column added to the FLOC/EQ details

IMSFB-17266

The completeness indicator was added to the FLOC/Equipment main grid.

Figure 65: Completeness indicator on FLOC / Equipment details screen.

 

7. Change/Deferrals Awaiting Approval Filter

IMSFB-15560

The “Awaiting Approval” filter was changed to reflect the Tier Level statuses.

The “My Approvals” section now shows not all the Requests, on which the user is defined as approver, but only those Requests, which are currently on the tier level, to which the user is assigned to.

Thus, if the user is not first in line for the approvals, this request will not be taken into account for the counts.

Figure 66: CHD dashboard - My Approvals section.

 

Figure 67: User is not first in line for the approvals.

 

Figure 68: User is first in line for the approvals.

 

Figure 69: CHD dashboard - My Approvals section is updated.

 

Resolved issues